Adsorptive materials and process for producing them

Abstract: The specification relates to an adsorptive material for removing malodorous substances from gases and liquids. The adsorptive material comprises a substrate having macromonomers which are bonded to the substrate and contain functional groups capable of adsorbing polar substances. The adsorptive material is produced by applying to the substrate a mixture of a monosaccharide and the macromonomers and then grafting the macromonomers to the substrate.

Description: This invention relates to adsorptive materials for removing malodorous substances from gases and liquids, as well as a process for producing such adsorptive materials. More particularly, this invention relates to adsorptive materials for removing malodorous substances in such items as clothes, bedclothes, pillow covers as well as animal laboratories, residences, hospitals and automobiles and to a process for producing such adsorptive materials. With recent improvements in living standards, not only the malodor from industrial plants but also malodor originating from various sources in everyday life such as toilets, garbage, sewage and pet animals have become a social concern. The causative substances of malodor include, for example, ammonia, amines, hydrogen sulfide and mercaptans. Various methods are available for removing malodors originating from everyday life and they include, for example: spraying or evaporating fragrance substances; cleaning with chemicals such as acids or alkalies; adsorbing malodorous substances on zeolite or bentonite; using catalysts or oxidizers; and neutralizing malodorous substances with ion exchangers. JP-A-2-69123 teaches a chemical for clearing excretions from pet animals. The chemical comprises a water-absorbing polymeric powder that is incorporated in a powder comprising a nonmetallic mineral having ion-exchange capability and adsorptive power. JP-B-3-8738 teaches a dry particulate material for treating excretions from domesticated animals and contains chemical pulp, mechanical pulp or semichemical pulp and an inorganic filler. US-A-4,076,619 teaches a crosslinked acrylic polymer capable of selective adsorption of waste matter as excreted by fish and shellfish in seawater. However, these conventional methods have been unable to yield completely satisfactory results since their ability to remove malodorous substances is either insufficient or limited to particular substances. The present invention has been accomplished under these circumstances and has as an object of providing an adsorptive material that is capable of adsorbing a wide spectrum of malodorous substances with improved efficiency. This object of the present invention can be attained by an adsorptive material comprising a substrate and a polymerized material derived from monomers having functional groups capable of adsorbing polar substances, said polymerized material having a degree of polymerization of from 10 to 100 and containing (a) units derived from at least one monomer selected from hydroxyethyl methacrylate, hydroxypropyl acrylate, vinylpyrrolidone, dimethylacrylamide, ethylene glycol monomethacrylate, ethylene glycol monoacrylate, ethylene glycol dimethacrylate, ethylene glycol diacrylate, triethylene glycol diacrylate and triethylene glycol methacrylate; and (b) units derived from at least one monomer selected from acrylic acid, methacrylic acid, styrenesulfonic acid and salts thereof, 2-acrylamido-2-methylpropanesulfonic acid, glycidyl methacrylate, glycidyl acrylate, vinylbenzyltrimethyl ammonium salt, diethylaminoethyl methacrylate, dimethylaminoethyl acrylate, dimethylaminoethyl methacrylate, diethylaminoethyl acrylate, diethylaminomethyl methacrylate, tertiary-butylaminoethyl acrylate, tertiary-butylaminoethyl methacrylate, dimethylaminopropyl acrylamide and chloromethylstyrene; or containing units derived from vinylbenzyltrimethyl ammonium salt and acrylic acid. The substrate of the adsorptive material of the present invention is not limited to any particular type, and any materials that permit the binding of the polymerized material can be used. Substrates that can be used in the present invention include, for example, celluloses, polyolefins, polyacrylonitriles, polyesters such as PET and PBT, polyamides such as nylon 6 and nylon 66, animal hairs, natural leather and synthetic leather, as well as combinations of these. Typical examples of the celluloses that can be used as the substrate include wood celluloses such as paper pulp and wood chips. In addition to these celluloses, leaf fiber cellulose, stem fiber cellulose and seed tomentous or pubescent fiber cellulose may also be used. Examples of such celluloses include bast fibers (e.g., hemp, flax, ramie and Manila hemp) and cotton. If desired, rice straw, coffee bean husk, spent tea leaves, soy pulp and other waste may be recycled for use as cellulose. Such waste is very convenient to use as substrates because it does not require any special preliminary treatments. A particularly preferred cellulose for use in the present invention is paper pulp. Examples of polyolefins that can be used as a substrate include polyethylene and polypropylene. If desired, these materials may be partly replaced by halogens such as chlorine and fluorine, hydroxyl group, etc. A preferred polyolefin is polyethylene. Examples of animal hairs that can be used as substrates include wool, camel hair, alpaca, cashmere, mohair, goat hair, rabbit hair and silk. Examples of natural leather that can be used as substrates include cowskin, goatskin and the skin or hide of reptiles. Examples of synthetic leather that can be used as substrates include CORFAM® of Du Pont, CLARINO® of Kuraray and ESCAINE® of Toray. The substrate of the adsorptive material of the present invention has the function of serving as a structural member that supports the polymerized material having functional groups capable of adsorbing polar substances, increases the area of adsorption, retains the shape of the adsorptive material and imparts the necessary strength. Hence, the substrate itself is generally a material that is essentially nonreactive, or inert, to polar substances. On the other hand, polar substances are to be adsorbed by the polymerized material to be described hereinafter. Thus, one of the major features of the present invention is that the substrate and the polymerized material, respectively assume two different parts of the function of the adsorptive material. As a result, the adsorptive material of the present invention has an increased area of adsorption while exhibiting physical and chemical stability. Unlike the adsorptive material of the present invention, conventional ion-exchange resins do not rely upon the substrate and functional groups to perform different functions since they have been produced by a process in which a polymerizable monomer having ion-exchange groups is polymerized to form a high-molecular material. The shape of the substrate is not limited in any particular way and various shapes may be employed as selected from among fibers, films, flakes, powders, sheets, mats and spheres. From the viewpoint of maximizing the area of adsorption and enhancing the efficiency of adsorption, the use of fibrous materials is advantageous. It is particularly advantageous to use fibrous materials having fiber diameters of from about 1 to about 50 µm. One of the reasons why fibrous materials are advantageous is that they can be easily worked into a desired shape and assembled in a module. Further, fibrous materials have no potential to release fine particles or dust into the atmosphere and, hence, they can be used in semiconductors and other areas of precision machining. If fibrous materials are to be used, they may be staple fibers or filaments. Such fibers may be processed into woven or nonwoven fabrics. If fibrous materials are to be used in a spherical form, their diameter is advantageously adjusted to lie between about 2 and 20 mm from the viewpoint of ease of handling. It should also be mentioned that if the adsorptive material of the present invention employs a fibrous substrate, it may be used in admixture with other fibrous materials. The polymerized material that is bonded to the substrate of the adsorptive material of the present invention and which has functional groups capable of adsorbing polar substances comprises the product of polymerization of reactive monomers described below. The polymerized material to be used in the present invention is derived from reactive monomers having functional groups capable of adsorbing polar substances and has a degree of polymerization of from 10 to 100. As will be described later in this specification, the adsorptive material of the present invention is produced by grafting to the substrate the polymerized material which has functional groups capable of adsorbing polar substances. Therefore, the adsorptive material of the present invention and a graft polymer that is produced by graft polymerization of reactive monomers onto a substrate are distinguished from each other in terms of both chemical structure and production process. Functional groups to be used in the present invention that have the ability to adsorb polar substances include, for example hydrophilic groups, cationically dissociating groups and anionically dissociating groups. Preferably, the functional groups comprise hydrophilic groups and cationically dissociating groups and/or anionically dissociating groups. Stated more specifically, the polymerized material contains preferably either two kinds of functional groups (i.e., hydrophilic groups and cationically dissociating groups, or hydrophilic groups and anionically dissociating groups) or three kinds of functional groups (i.e., hydrophilic groups, cationically dissociating groups and anionically dissociating groups). Thus, one of the major features of the adsorptive material of the present invention is that hydrophilic groups (nonions) are present in combination with ionic groups (cations and/or anions). Hydrophilic groups, cationically dissociating groups and anionically dissociating groups are introduced into the polymerized material by insuring that reactive monomers having these groups (to be described below) are polymerized to a degree of polymerization within the range specified above (i.e., 10 - 100). Stated more specifically, the polymerized material can generally be prepared by polymerizing a solution containing a mixture of certain reactive monomers that have the functional groups described above. Various methods of polymerization may be employed, such as polymerization in the presence of a polymerization initiator, thermal polymerization and ionizing radiation initiated polymerization. In these cases, the desired degree of polymerization can be attained by controlling the reaction conditions in an appropriate manner. In the case of ionizing radiation initiated polymerization, ultraviolet rays, electron beams, X-rays, α-rays, β-rays, γ-rays, etc. may be used. Thus, the resulting polymerized material comprises reactive monomers having hydrophilic groups and reactive monomers having cationically dissociating groups and/or reactive monomers having anionically dissociating groups. When preparing the polymerized material, the molar ratio at which the reactive monomers having hydrophilic groups, the reactive monomers having cationically dissociating groups and the reactive monomers having anionically dissociating groups are to be mixed can be selected as appropriate for such factors as the use and performance of the adsorptive material to be finally produced. To give just one example, a solution comprising a mixture of about 5 to about 20 mol% of the reactive monomers having hydrophilic groups, about 30 to about 50 mol% of the reactive monomers having cationically dissociating groups, and about 30 to about 50 mol% of the reactive monomers having anionically dissociating groups may be polymerized to produce the macromonomer. There is no particular limitation on the mode in which the reactive monomers having hydrophilic groups and the reactive monomers having cationically and/or anionically dissociating groups are arranged in the polymerized material. Therefore, the reactive monomers having hydrophilic groups and the reactive monomers having cationically and/or anionically dissociating groups may be arranged alternately, in blocks, randomly or in grafts. The mode of arrangement of these reactive monomers depends on the reaction conditions or the type of reactive monomers to be used when producing the polymerized material and appropriate reaction conditions can be selected by anyone skilled in the art. The term "hydrophilic groups" as used herein means those groups which have affinity for water and which will not dissociate ionically upon contact with water; in other words, hydrophilic groups are nonions. Such hydrophilic groups are capable of trapping the water molecules present in air and the trapped water molecules are capable of forming a layer of adsorbed water on the surface of the adsorptive material of the present invention, thereby dissolving polar substances and/or dissociating ionic substances. Needless to say, such hydrophilic groups will function in water in the same manner as in air. Examples of such hydrophilic groups include a hydroxyl group, a hydroxyalkyl group (where the alkyl group is preferably a lower alkyl group), an amino group and a pyrrolidonyl group. Preferred hydrophilic groups include a hydroxyl group, a hydroxyalkyl group and a pyrrolidonyl group. One or more kinds of hydrophilic groups may be introduced into the polymerized material. The reactive monomers that have such hydrophilic groups and which can be used according to the present invention are hydroxyethyl methacrylate, hydroxypropyl acrylate, vinylpyrrolidone, dimethylacrylamide, ethylene glycol monomethacrylate, ethylene glycol monoacrylate, ethylene glycol dimethacrylate, ethylene glycol diacrylate, triethylene glycol diacrylate and triethylene glycol methacrylate. Among these, hydroxyethyl methacrylate and vinylpyrrolidone are particularly useful hydrophilic monomers. The term "cationically dissociating groups" as used herein means those ion-exchange groups whose counterion is a cation. A typical cationically dissociating group is an acid group. Cationically dissociating groups have the ability to adsorb polar substances and are capable of releasing a proton (hydrogen ion) to enter into neutralizing reaction with basic substances, say, ammonia or amines. As a result, the basic substances will be removed. One or more kinds of cationically dissociating groups may be introduced into the polymerized material. Examples of such cationically dissociating groups include a carboxyl group, a sulfone group, a phosphate group, a sulfoethyl group, a phosphomethyl group, a carbomethyl group. Preferred cationically dissociating groups include a sulfone group and a carboxyl group. The reactive monomers that have such cationically dissociating groups and which can be used according to the present invention are acrylic acid, methacrylic acid, styrenesulfonic acid and salts thereof, and 2-acrylamido-2-methylpropanesulfonic acid. Also useful and employable according to the present invention are reactive monomers that have groups capable of conversion to cationically dissociating groups, i.e., glycidyl methacrylate and glycidyl acrylate. The term "anionically dissociating groups" as used herein means those ion-exchange groups whose counterion is an anion. Therefore, anionically dissociating groups have the ability to absorb polar substances and are capable of entering into neutralizing reaction with acidic substances, say, hydrogen sulfide or mercaptans. As a result, the acidic substances will be removed. One or more kinds of anionically dissociating substances may be introduced into the polymerized material. Examples of such anionically dissociating groups include a quaternary ammonium salt and primary, secondary and tertiary amino groups such as an amino group, a methylamino group, a dimethylamino group and a diethylamino group. Preferred anionically dissociating groups include a quaternary ammonium salt and an amino group. The reactive monomers that have such anionically dissociating groups and can be used according to the present invention are vinylbenzyltrimethyl ammonium salt, diethylaminoethyl methacrylate, dimethylaminoethyl acrylate, dimethylaminoethyl methacrylate, diethylaminoethyl acrylate, diethylaminomethyl methacrylate, tertiary-butylaminoethyl acrylate, tertiary-butylaminoethyl methacrylate and dimethylaminopropylacrylamide. Among these, vinylbenzyltrimethyl ammonium salt and diethylaminoethyl methacrylate are particularly useful. Also useful and employable in the present invention is a reactive monomer that has a group capable of conversion to an anionically dissociating group, i.e., chloromethylstyrene. In the present invention, one or more kinds of hydrophilic groups may be present in the polymerized material. This is also true with cationically dissociating groups and anionically dissociating groups and one or more kinds of each group may be present in the polymerized material. Combinations of functional groups that are preferred in the present invention may specifically be exemplified by the one of a sulfone group with a carboxyl group, a quaternary ammonium group and a hydroxyethyl group. Another specific preferred example of the combination of functional groups is the one of a sulfone group with a carboxyl group, a quaternary ammonium salt and a pyrrolidonyl group. Needless to say, the thus prepared polymerized material which has functional groups capable of adsorbing polar substances could be used as such without being bonded to the substrate. Thus, the polymerized material could be diluted and charged into a spray can for subsequent use as an aerosol-type deodorizing spray. However, in the present invention, the polymerized material is bonded to the substrate considering the fact that the use of the adsorptive material is expanded by immobilizing the polymerized material on the substrate of an existing shape in a manner that is stable both physically and chemically. In the adsorptive material of the present invention, the polymerized material is bonded chemically to the substrate. While any known binding methods may be employed, graft polymerization techniques to be described below, in particular, radiation initiated graft polymerization that uses monosaccharides are preferably employed. The adsorptive material of the present invention performs adsorption by the following mechanism. The adsorptive material comprises the substrate for retaining its shape and imparting the necessary strength, as well as the polymerized material which binds to said substrate. The polymerized material contains functional groups having the ability to adsorb polar substances, in particular, hydrophilic groups and cationically dissociating groups and/or anionically dissociating groups. Consider here the case of adsorption in air; the water molecules that are present in air are attracted towards the surface of the adsorptive material by means of hydrophilic groups and then adsorbed on that surface. Thus, the layer of adsorbed water comprising a number of adsorbed water molecules is formed on the surface of the adsorptive material. Acidic or basic substances will be trapped on the surface of the adsorptive material by interaction with the cationically or anionically dissociating groups while, at the same time, they are also trapped on the surface of the adsorptive material by the action of adsorbed water. The thus trapped substances will dissociate in the layer of adsorbed water to be neutralized with cationically or anionically dissociating groups. As for ordinary polar substances, their affinity for water causes them to be dissolved in the layer of adsorbed water. Thus, the presence of hydrophilic groups and cationically and/or anionically dissociating groups in the adsorptive material of the present invention enhances not only the adsorbability of target substances but also their tendency for dissociation. In short, the adsorptive material of the present invention is in such a state that adsorption, dissociation and reaction for neutralization are most likely to occur, causing two kinds of adsorption, one being physical adsorption that involves dissolution in water and the other being chemical adsorption which involves dissociation into ions and neutralization. The substances to be adsorbed on the adsorptive material of the present invention by the mechanism described above may be of any types as long as they are polar substances. Preferably, they are acidic substances such as mercaptan and hydrogen sulfide, or basic substances such as ammonia and amine containing substances. While the mechanism of adsorption by the adsorptive material of the present invention has been described above with reference to the case where adsorption occurs in air, it will be apparent to one skilled in the art that the same mechanism will apply to adsorption that occurs in water. As described above, the adsorptive material of the present invention permits efficient removal of various polar substances and, hence, it can be used in a broad scope of applications including padding for suits, feed materials for animals, air conditioning filters, articles for use in hospitals (e.g., pillows and bed sheets), filters in automotive air conditioners, refrigerators, in soles for shoes, disposable diapers and fast food kitchens. In addition to the above-described adsorptive material, the present invention also provides a process for producing said adsorptive material. Stated more specifically, the present invention also provides a process for producing an adsorptive material comprising a substrate and a polymerized material having a degree of polymerization of from 10 to 100 and being derived from monomers having functional groups capable of adsorbing polar substances which process comprises the steps of applying to said substrate a mixture of a monosaccaride and said polymerized material and then grafting said polymerized material to said substrate. In the current practice of grafting polymerized materials to substrates, the low affinity between the surfaces of the two members prevents effective grafting of the polymerized material to the substrate and, instead, the polymerized material undergoes homopolymerization which will proceed independently of the intended graft polymerization. Hence, it has been very difficult to graft the polymerized material onto the surface of the substrate. The process of the present invention eliminates these defects of the prior art and renders it possible to have the polymerized material grafted efficiently onto the substrate. To implement the process of the present invention, the substrate already described in connection with the first aspect of the invention is formed into a desired shape, say, a woven cloth of fibers and, thereafter, a mixture of the polymerized material and a monosaccharide is applied to the shaped substrate. The polymerized material is such that it has been prepared by the method already described in connection with the first aspect of the invention. The method of applying the mixture of the polymerized material and the monosaccharide to the substrate is in no way limited and various means of application can be employed as exemplified by coating with a brush or a doctor blade, spraying, and impregnation. The proportions at which the polymerized material and the monosaccharide are to be mixed are by no means critical for the purposes of the present invention and they can be determined appropriately by one skilled in the art in such a way as to provide a desired graft ratio. For example, the monosaccharide is added generally in an amount of from about 0.1 to about 10 wt%, preferably from about 0.5 to about 5 wt%, more preferably from about 1 to about 3 wt%, on the basis of the total weight of the polymerized material. If the substrate is fibrous, the fiber diameter is preferably from about 1 to about 50 µm because this range insures graft polymerization to take place uniformly in fiber cross sections. After the substrate is impregnated with the mixture of the polymerized material and the monosaccharide, the excess portion of the mixture is removed from the substrate and the remaining portion is subjected to graft polymerization. There is no particular limitation on the method of graft polymerization and various techniques can be employed, including polymerization in the presence of a polymerization initiator, thermal polymerization in the presence of a reaction initiator, thermal polymerization and ionizing radiation initiated polymerization. Graft polymerization to be initiated by exposure to ionizing radiation is preferably employed in the present invention. Examples of the ionizing radiation that can be used include ultraviolet rays, electron beams, X-rays, α-rays, β-rays, γ-rays, etc. For practical applications, γ-rays or electron beams are preferably used. The graft ratio is in no way limited in the present invention but it is preferably no more than about 150%, with the range from about 50 to about 100% being particularly preferred. If the graft ratio is excessive, the inherent properties of the substrate will be impaired to increase the chance of its failure to perform the intended functions already described above. One of the major features of the process of the present invention is to use monosaccharides in graft polymerization. The purpose of using monosaccharides is to achieve a marked improvement in the efficiency of grafting the polymerized material onto the substrate. The use of monosaccharides improves the graft ratio probably because they accelerate the impregnation of the polymerized material into the substrate. As a result, chemical bonds will be easily formed between the polymerized material and the substrate by graft polymerization, accompanied by corresponding decrease in the homopolymerization between molecules of the polymerized material. Therefore, it is believed that monosaccharides will participate in the formation of chemical bonds between the polymerized material and the substrate but they would not probably be part of the formed chemical bonds. The monosaccharides to be used in the process of the present invention are aldoses or ketoses represented by the general formula C n H 2n O n , where n is an integer of 2 - 10. Aldoses are preferably used in the present invention and it is particularly preferred to use glucose which is aldohexose (n = 6). The adsorptive material of the present invention contains not only hydrophilic groups but also cationically dissociating groups and/or anionically dissociating groups; hence, said material is capable of adsorbing acidic or basic substances while achieving simultaneous adsorption of ordinary polar substances. What is more, the efficiency of their adsorption is extremely high. When implementing the process of the present invention for producing the adsorptive material, the efficiency of grafting the polymerized material onto the substrate can be enhanced markedly by using monosaccharides. The following examples are provided for the purpose of further illustrating the present invention but are in no way to be taken as limiting. Example 1 A glass container was charged with 1 L of an aqueous solution containing a mixture of sodium styrenesulfonate (100 g), acrylic acid (100 g) and vinylpyrrolidone (10 g). High-purity nitrogen was bubbled through the aqueous solution for 1 min to replace the dissolved oxygen. Subsequently, the aqueous solution was irradiated with a uv radiation (200 W) at 40°C for 1 h, thereby effecting polymerization to prepare a polymerized material. The degree of polymerization of the polymerized material was about 80. Glucose (10 g) was added to the resulting polymerized material solution and dissolved thoroughly to prepare a solution comprising a mixture of the polymerized material and glucose. Flakes of regenerated paper having an average diameter of 5 mm were immersed in an equal volume of the mixture solution for 10 min. Subsequently, the regenerated paper was recovered from the mixture solution, stripped of excess residual liquid and charged into an irradiation vessel. After deoxygenating the interior of the vessel, the regenerated paper was irradiated with γ-rays from cobalt 60 at a dose rate of 10 kGy/h for 2 h at room temperature, whereby the polymerized material was grafted onto the regenerated paper to produce a sample of the invention's adsorptive material. The absorbed dose was 20 kGy. The sample was washed thoroughly with warm water to remove the unreacted polymerized material and the homopolymer of the polymerized material. Thus an adsorptive material was obtained such that the polymerized material containing pyrrolidonyl, carboxyl and sulfone groups was bonded thereto. After drying, the change in the weight of the adsorptive material was measured and the graft ratio was found to be 95 wt% of the impregnant polymerized material. The adsorptive material had no detectable deposit of a homopolymer of the polymerized material. Measurement of ion-exchange capacity showed that 4.0 mmol of cation-exchange groups had been introduced per gram of the adsorptive material. The thus produced adsorptive material was then tested for its adsorbing performance. A portion (20 g) of the adsorptive material was placed in the central square part (10 cm per side) of the bottom of a polyacrylic container having a capacity of 150 L. Ammonia was supplied into the container to give an initial concentration of 100 ppm. The concentration of ammonia in the container was measured with a GASTEC® detector at predetermined time intervals. The measurement was continued until the concentration of ammonia in the container dropped from 100 ppm to 20 ppm. When the ammonia concentration reached 20 ppm, ammonia was supplied again into the container to give a concentration of 100 ppm, followed by another measurement until the concentration dropped to 20 ppm. This operation was repeated and the point of time at which the concentration of ammonia would no longer reach 20 ppm after passage of 5 h was regarded as "breakthrough". The adsorption capacity of the adsorptive material was calculated from the integration of the amount of ammonia that had been adsorbed until breakthrough was reached and the result was 3.5 mmol/g. For comparison, a commercial grade of deodorizing activated charcoal was measured for its adsorption capacity by the same method and the result was 0.03 mmol/g. It is therefore clear that the adsorptive material of the present invention had an extremely large adsorption capacity. Comparative Example 1 A polymerized material was prepared by the same procedure as in Example 1. Then, the polymerized material was grafted onto regenerated paper by the same procedure as in Example 1, except that no glucose was used. The resulting adsorptive material had a homopolymer of the polymerized material formed on the surface of the regenerated paper and the homopolymer came off the substrate upon washing with warm water. The dried adsorptive material was brittle. The change in the weight of the adsorptive material was measured and the graft ratio was found to be 30% of the impregnant polymerized material. Measurement of ion-exchange capacity showed that 0.7 mmol of cation-exchange groups had been introduced per gram of the adsorptive material. In the next place, the thus produced adsorptive material was tested for its adsorbing performance by the same procedure as in Example 1. The adsorption capacity of the adsorptive material was found to be 0.3 mmol/g. Thus, it was clear that when the polymerized material was grafted onto the substrate without using the monosaccharide glucose, not only the efficiency of polymerization but also the adsorption capacity of the resulting adsorptive material was low. Comparative Example 2 In this comparative example, reactive monomers were directly grafted to the substrate without preparing a polymerized material. Regenerated paper was impregnated in an aqueous mixture solution for polymerized material preparation as used in Example 1, and graft polymerization was conducted by the same method as in Example 1. As a result, the aqueous mixture solution moved to the bottom of the irradiation vessel, producing homopolymers in blocks. The graft ratio was 40% of the impregnant reactive monomers. Measurement of ion-exchange capacity showed that 1.2 mmol of cation-exchange capacity showed that 1.2 mmol of cation-exchange groups had been introduced per gram of the adsorptive material. In the next place, the thus produced adsorptive material was tested for its adsorbing performance by the same procedure as in Example 1. The adsorption capacity of the adsorptive material was found to be 1.0 mmol/g. Thus, it was clear that when reactive monomers were directly grafted onto the substrate without preparing a polymerized material, not only the efficiency of polymerization but also the adsorption capacity of the resulting adsorptive material was low. Example 2 A glass container was charged with 1 L of an aqueous solution containing a mixture of diethylaminoethyl methacrylate (300 g) and hydroxyethyl methacrylate (50 g). High-purity nitrogen was bubbled through the aqueous solution for 1 min to replace the dissolved oxygen. Subsequently, the aqueous solution was irradiated with γ-rays from cobalt 60 at a dose rate of 0.1 kGy/h for 1 h at room temperature to prepare a polymerized material. The degree of polymerization of the polymerized material was about 85. Glucose (10 g) was added to the resulting polymerized material solution and dissolved thoroughly to prepare a solution comprising a mixture of the polymerized material and glucose. A polyethylene filter cloth having a fiber diameter of 25 µm was immersed in an equal volume of the mixture solution for 10 min. Subsequently, the filter cloth was recovered from the mixture solution, stripped off excess residual liquid and charged into an irradiation vessel. After deoxygenating the interior of the vessel, the filter cloth was irradiated with γ-rays from cobalt 60 at a dose rate of 10 kGy/h for 2 h at room temperature, whereby the polymerized material was grafted onto the filter cloth to produce a sample of the invention's adsorptive material. The adsorbed dose was 20 kGy. The sample was washed thoroughly with warm water to remove the, unreacted polymerized material and the homopolymer of the polymerized material. Thus, an adsorptive material was obtained such that the polymerized material containing hydroxyethyl and diethylamino groups was bonded thereto. After drying, the change in the weight of the adsorptive material was measured and the graft ratio was found to be 98 wt% of the impregnant polymerized material. The adsorptive material had no detectable deposit of a homopolymer of the polymerized material. Measurement of ion-exchange capacity showed that 3.5 mmol of anion-exchange groups had been introduced per gram of the adsorptive material. In the next place, the thus produced adsorptive material was tested for its adsorbing performance by the same procedure as in Example 1, except that acetic acid was used instead of ammonia. The adsorptive material was found to have an adsorption capacity of 3.5 mmol/g. For comparison, a commercial grade of deodorizing activated charcoal was measured for its adsorption capacity by the same method and the result was 0.01 mmol/g. It is therefore clear that the adsorptive material of the present invention had an extremely large adsorption capacity. Comparative Example 3 A polymerized material was prepared by the same procedure as in Example 2. Then, the polymerized material was grafted onto a polyethylene filter cloth by the same procedure as in Example 2, except that no glucose was used. The resulting adsorptive material had a homopolymer of the polymerized material formed on the surface of the filter cloth and the homopolymer came off the substrate upon washing with warm water. The change in the weight of the adsorptive material was measured and the graft ratio was found to be 45% of the impregnant macromonomer. Measurement of ion-exchange capacity showed that 1.3 mmol of anion-exchange groups had been introduced per gram of the adsorptive material. In the next place, the thus produced adsorptive material was tested for its adsorbing performance by the same procedure as in Example 2. The adsorption capacity of the adsorptive material was found to be 1.0 mmol/g. Thus, it was clear that when the polymerized material was grafted onto the substrate without using the monosaccharide glucose, not only the efficiency of polymerization but also the adsorption capacity of the resulting adsorptive material was low. Comparative Example 4 In this comparative example, reactive monomers were directly grafted to the substrate without preparing a polymerized material. Polyethylene filter cloth was impregnated in an aqueous mixture solution for polymerized material preparation as used in Example 2, and graft polymerization was conducted by the same method as in Example 2. As a result, the aqueous mixture solution moved to the bottom of the irradiation vessel, producing homopolymers in blocks. The graft ratio was 20% of the impregnant reactive monomers. Measurement of ion-exchange capacity showed that 0.6 mmol of cation-exchange groups had been introduced per gram of the adsorptive material. In the next place, the thus produced adsorptive material was tested for its adsorbing performance by the same procedure as in Example 1. The adsorption capacity of the adsorptive material was found to be 0.5 mmol/g. Thus, it was clear that when reactive monomers were directly grafted onto the substrate without preparing a polymerized material, not only the efficiency of polymerization but also the adsorption capacity of the resulting adsorptive material was low. Example 3 A glass container was charged with 1 L of an aqueous solution containing a mixture of dimethylaminoethyl acrylate (300 g) and vinylpyrrolidone (100 g). High-purity nitrogen was bubbled through the aqueous solution for 1 min to replace the dissolved oxygen. Subsequently, the aqueous solution was irradiated with γ-rays from cobalt 60 at a dose rate of 0.5 kGy/h for 1 h at room temperature to prepare a polymerized material. The degree of polymerization of the polymerized material was about 90. Glucose was added to the resulting polymerized material solution in an amount of 1% of the total quantity of the polymerized material and dissolved thoroughly to prepare a solution comprising a mixture of the polymerized material and glucose. A nonwoven polyethylene terephthalate fabric having a fiber diameter of 30 µm was immersed in an equal volume of the mixture solution for 10 min. Subsequently, the nonwoven fabric was recovered from the mixture solution, striped off excess residual liquid and charged into an irradiation vessel. After deoxygenating the interior of the vessel, the nonwoven fabric was irradiated with γ-rays from cobalt 60 at a dose rate of 10 kGy/h for 2 h at room temperature, whereby the polymerized material was grafted onto the nonwoven fabric to produce a sample of the invention's adsorptive material. The sample was washed thoroughly with warm water to remove the unreacted polymerized material and the homopolymer of the polymerized material. Thus, an adsorptive material was obtained such that the polymerized material containing pyrrolidonyl and dimethylamino groups was bonded thereto. After drying, the change in the weight of the adsorptive material was measured and the graft ratio was found to be 95 wt% of the impregnant polymerized material. The adsorptive material had no detectable deposit on a homopolymer of the polymerized material. Measurement of ion-exchange capacity showed that 3.0 mmol of anion-exchange groups had been introduced per gram of the adsorptive material. Example 4 A glass container was charged with 1 L of an aqueous solution containing a mixture of dimethylaminoethyl methacrylate (300 g) and triethylene glycol diacrylate (100 g). High-purity nitrogen was bubbled through the aqueous solution for 1 min to replace the dissolved oxygen. Subsequently, the aqueous solution was irradiated with γ-rays from cobalt 60 at a dose rate of 1.0 kGy/h for 1 h at room temperature to prepare a polymerized material. The degree of polymerization of the polymerized material was about 100. Glucose was added to the resulting polymerized material solution in an amount of 5% of the total quantity of the polymerized material and dissolved thoroughly to prepare a solution comprising a mixture of the polymerized material and glucose. A nonwoven nylon 66 fabric having a fiber diameter of 25 µm was immersed in an equal volume of the mixture solution for 10 min. Subsequently, the nonwoven fabric was recovered from the mixture solution, stripped of excess residual liquid and charged into an irradiation vessel. After deoxygenating the interior of the vessel, the nonwoven fabric was irradiated with γ-rays from cobalt 60 at a dose rate of 10 kGy/h for 2.5 h at room temperature, whereby the polymerized material was grafted onto the nonwoven fabric to produce a sample of the invention's adsorptive material. The sample was washed thoroughly with warm water to remove the unreacted polymerized material and the homopolymer of the polymerized material. After drying, the change in the weight of the adsorptive material was measured and the graft ratio was found to be 90 wt% of the impregnant polymerized material. The adsorptive material had no detectable deposit of a homopolymer of the polymerized material. Measurement of ion-exchange capacity showed that 2.0 mmol of anion-exchange groups had been introduced per gram of the adsorptive material. Example 5 A glass container was charged with 1 L of an aqueous solution containing a mixture of sodium styrenesulfonate (150 g), acrylic acid (150 g) and hydroxyethyl methacrylate (150 g). High-purity nitrogen was bubbled through the aqueous solution for 1 min to replace the dissolved oxygen. Subsequently, the aqueous solution was irradiated with γ-rays from cobalt 60 at a dose rate of 0.1 kGy/h for 1 h at room temperature to prepare a polymerized material. The degree of polymerization of the polymerized material was about 80. Glucose was added to the resulting polymerized material solution in an amount of 2% the total quantity of the polymerized material and dissolved thoroughly to prepare a solution comprising a mixture of the polymerized material and glucose. Scoured wool yarns were immersed in an equal volume of the mixture solution for 1 min. Subsequently, the yarns was recovered from the mixture solution, stripped off excess residual liquid and charged into an irradiation vessel. After deoxygenating the interior of the vessel, the yarns were irradiated with γ-rays from cobalt 60 at a dose rate of 10 kGy/h for 2 h at room temperature, whereby the polymerized material was grafted onto the yarns to produce a sample of the invention's adsorptive material. The sample was washed thoroughly with warm water to remove the unreacted polymerized material and the homopolymer of the polymerized material. After drying, the change in the weight of the adsorptive material was measured and the graft ratio was found to be 98 wt% of the impregnant polymerized material. The adsorptive material had no detectable deposit of a homopolymer of the polymerized material. Measurement of ion-exchange capacity showed that 4.5 mmol of cation-exchange groups had been introduced per gram of the adsorptive material. Example 6 A glass container was charged with 1 L of an aqueous solution containing a mixture of dimethylaminopropyl acrylamide (300 g) and ethylene glycol dimethacrylate (100 g). High-purity nitrogen was bubbled through the aqueous solution for 1 min to replace the dissolved oxygen. Subsequently, the aqueous solution was irradiated with γ-rays from cobalt 60 at a dose rate of 0.1 kGy/h for 1 h at room temperature to prepare a polymerized material. The degree of polymerization of the polymerized material was about 90. Glucose was added to the resulting polymerized material solution in an amount of 3% of the total quantity of the polymerized material and dissolved thoroughly to prepare a solution comprising a mixture of the polymerized material and glucose. Sheep skin was immersed in an equal volume of the mixture solution for 10 min. Subsequently, the sheep skin was recovered from the mixture solution, stripped of excess residual liquid and charged into an irradiation vessel. After deoxygenating the interior of the vessel, the sheep skin was irradiated with γ-rays from cobalt 60 at a dose rate of 10 kGy/h for 2.5 h at room temperature, whereby the polymerized material was grafted onto the sheep skin to produce a sample of the invention's adsorptive material. The sample was washed thoroughly with warm water to remove the unreacted polymerized material and the homopolymer of the polymerized material. After drying, the change in the weight of the adsorptive material was measured and the graft ratio was found to be 93 wt% of the impregnant polymerized material. The adsorptive material had no detectable deposit of a homopolymer of the polymerized material. Measurement of ion-exchange capacity showed that 3.0 mmol of anion-exchange groups had been introduced per gram of the adsorptive material. Example 7 A glass container was charged with 1 L of an aqueous solution containing a mixture of vinylbenzyltrimethyl ammonium salt (300 g) and acrylic acid (300 g). High-purity nitrogen was bubbled through the aqueous solution for 1 min to replace the dissolved oxygen. Subsequently, the aqueous solution was irradiated with γ-rays from cobalt 60 at a dose of 0.1 kGy/h for 1 h at room temperature to prepare a polymerized material. The degree of polymerization of the polymerized material was about 95. Glucose was added to the resulting polymerized material solution in an amount of 5% of the total quantity of the polymerized material and dissolved thoroughly to prepare a solution comprising a mixture of the polymerized material and glucose. CLARINO®, synthetic leather of Kuraray Co., Ltd., was immersed in an equal volume of the mixture solution for 10 min. Subsequently, the leather was recovered from the mixture solution, stripped off excess residual liquid and charged into an irradiation vessel. After deoxygenating the interior of the vessel, the leather was irradiated with γ-rays from cobalt 60 at a dose rate of 10 kGy/h for 2 h at room temperature, whereby the polymerized material was grafted onto the leather to produce a sample of the invention's adsorptive material. The sample was washed thoroughly with warm water to remove the unreacted polymerized material and the hompolymer of the polymerized material. After drying, the change in the weight of the adsorptive material was measured and the graft ratio was found to be 95 wt% of the impregnant polymerized material. The adsorptive material had no detectable deposit of a homopolymer of the polymerized material. Measurement of ion-exchange capacity showed that 4.0 mmol of anion-exchange groups had been introduced per gram of the adsorptive material.

Claims: An adsorptive material comprising a substrate and a polymerized material derived from monomers having functional groups capable of adsorbing polar substances, said polymerized material having a degree of polymerization of from 10 to 100 and containing (a) units derived from at least one monomer selected from hydroxyethyl methacrylate, hydroxypropyl acrylate, vinylpyrrolidone, dimethylacrylamide, ethylene glycol monomethacrylate, ethylene glycol monoacrylate, ethylene glycol dimethacrylate, ethylene glycol diacrylate, triethylene glycol diacrylate and triethylene glycol methacrylate; and (b) units derived from at least one monomer selected from acrylic acid, methacrylic acid, styrenesulfonic acid and salts thereof, 2-acrylamido-2-methylpropanesulfonic acid, glycidyl methacrylate, glycidyl acrylate, vinylbenzyltrimethyl ammonium salt, diethylaminoethyl methacrylate, dimethylaminoethyl acrylate, dimethylaminoethyl methacrylate, diethylaminoethyl acrylate, diethylaminomethyl methacrylate, tertiary-butylaminoethyl acrylate, tertiary-butylaminoethyl methacrylate, dimethylaminopropyl acrylamide and chloromethylstyrene; or containing units derived from vinylbenzyltrimethyl ammonium salt and acrylic acid. The adsorptive material according to claim 1 wherein said polymerized material is bonded to the substrate by graft polymerization. The adsorptive material according to any one of claims 1 - 2 wherein the substrate is in a fibrous form. The adsorptive material according to any one of claims 1 - 3 wherein the substrate comprises at least one material selected from cellulosic materials, polyolefins, halogenated polyolefins, polyacrylonitrile, animal hair, natural leather and synthetic leather. A process for producing an adsorptive material comprising a substrate and a polymerized material having a degree of polymerization of from 10 to 100 and being derived from monomers having functional groups capable of adsorbing polar substances which process comprises the steps of applying to said substrate a mixture of a monosaccaride and said polymerized material and then grafting said polymerized material to said substrate. The process of claim 5 wherein the monosaccharide is an aldohexose, preferably glucose. The process of claim 5 or 6 wherein grafting is effected by radiation initiated graft polymerization.

Inventors: OHKAWARA TADAYOSHI, SAITO KYOICHI, SUGO ETSUKO, OHKAWARA, TADAYOSHI, SAITO, KYOICHI, SUGO, ETSUKO
Applicants: ANGEL RESEARCH INST CO, ANGEL RESEARCH INSTITUTE CO.
Application year: 1994
Main classification: B01J20
IPC codes: B01J43, B01J20, B01D53, A61L9